U.S. patent application number 13/327939 was filed with the patent office on 2012-06-21 for method for coupling built-in components to each other in hollow container.
This patent application is currently assigned to YACHIYO INDUSTRY CO., LTD.. Invention is credited to Kazuhiro OHTAKI, Naoya TABUCHI, Takatoshi WATANABE.
Application Number | 20120152449 13/327939 |
Document ID | / |
Family ID | 45370440 |
Filed Date | 2012-06-21 |
United States Patent
Application |
20120152449 |
Kind Code |
A1 |
WATANABE; Takatoshi ; et
al. |
June 21, 2012 |
METHOD FOR COUPLING BUILT-IN COMPONENTS TO EACH OTHER IN HOLLOW
CONTAINER
Abstract
The present invention provides a method for coupling built-in
components in a hollow container, comprising: a hollow container
forming step of forming the hollow container, the hollow container
forming step including securing the built-in components to parisons
transferred onto mold pieces and closing the mold pieces with the
built-in components in a pre-in the pre-coupled state state; and a
built-in components coupling step of coupling the built-in
components, the built-in components coupling step including
pressing an outer surface of the hollow container to displace the
hollow container while cooling the hollow container after removing
the hollow container from the mold pieces.
Inventors: |
WATANABE; Takatoshi;
(Tochigi, JP) ; TABUCHI; Naoya; (Tochigi, JP)
; OHTAKI; Kazuhiro; (Tochigi, JP) |
Assignee: |
YACHIYO INDUSTRY CO., LTD.
Sayama-shi
JP
|
Family ID: |
45370440 |
Appl. No.: |
13/327939 |
Filed: |
December 16, 2011 |
Current U.S.
Class: |
156/245 |
Current CPC
Class: |
B29C 65/608 20130101;
B29C 2049/2047 20130101; B29C 66/636 20130101; B29C 2049/2008
20130101; B29C 51/267 20130101; B29K 2059/00 20130101; B29C 65/028
20130101; B29C 66/1312 20130101; B60K 15/03177 20130101; B29C
66/7234 20130101; B29C 65/58 20130101; B29C 66/83221 20130101; B29K
2023/065 20130101; B29C 66/71 20130101; B29C 66/12443 20130101;
B29K 2059/00 20130101; B29K 2023/065 20130101; B29C 66/54 20130101;
B29C 49/04 20130101; B29C 2791/001 20130101; B29C 2049/0057
20130101; B29C 2791/006 20130101; B29C 2791/007 20130101; B29C
66/73921 20130101; B29C 2049/2078 20130101; B29C 65/609 20130101;
B29C 66/543 20130101; B29C 51/12 20130101; B29C 66/71 20130101;
B29L 2031/7172 20130101; B60K 2015/03032 20130101; B29C 2049/2013
20130101; B29C 66/71 20130101 |
Class at
Publication: |
156/245 |
International
Class: |
B29C 65/56 20060101
B29C065/56 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 17, 2010 |
JP |
2010-281656 |
Claims
1. A method for coupling built-in components in a hollow container,
comprising: a hollow container forming step of forming the hollow
container, the hollow container forming step including securing the
built-in components to parisons transferred onto mold pieces and
closing the mold pieces with the built-in components in a pre-in
the pre-coupled state state; and a built-in components coupling
step of coupling the built-in components, the built-in components
coupling step including pressing an outer surface of the hollow
container to displace the hollow container while cooling the hollow
container after removing the hollow container from the mold
pieces.
2. The method of claim 1, wherein in the built-in components
coupling step, a correction jig is prepared, the correction jig
including a lower jig and a upper jig, the lower jig being for
placing the hollow container thereon, the upper jig being movable
up and down and having a pressing portion for pressing the outer
surface of the hollow container, the built-in components coupling
step further including: placing the hollow container on the lower
jig with the built-in components located at an upper surface part
and a lower surface part of the hollow container; and then bringing
the upper jig and the lower jig into proximity with each other to
cause the pressing portions to press only an area of the upper
surface part of the hollow container for correcting the hollow
container, the upper surface part area being a bearing surface to
which the built-in component is secured and a surrounding area
thereof.
3. The method of claim 1, wherein a pair of tubes are coupled for
communication with each other when the built-in components are
coupled during the built-in components coupling step.
4. The method of claim 2, wherein a pair of tubes are coupled for
communication with each other when the built-in components are
coupled during the built-in components coupling step.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the foreign priority benefit under
35 U.S.C. .sctn.119 of Japanese Patent Application No. 2010-281656
filed on Dec. 17, 2010 in the Japan Patent Office, the disclosure
of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method for coupling
built-in components to each other in a resin-made hollow container
such as a vehicle fuel tank.
[0004] 2. Description of the Invention
[0005] A vehicle fuel tank includes various built-in components
associated with the tank such as components related to a valve and
a pump, components for ensuring the strength of a tank body, and
components for restraining rippling of the fuel surface in the fuel
tank. For securing such built-in components to an inner wall of the
tank body, it is preferable to secure them during a step of
manufacturing the tank body rather than after completion of the
tank body when considering the labor or the like involved in
operations for incorporating the built-in components into the
completed tank body.
[0006] Examples of conventional methods of securing such components
during the step of manufacturing the tank body include a method
disclosed in JP 2009-542480. JP 2009-542480 describes a technique
of actuating an air cylinder in a center frame that is sandwiched
between mold pieces in opposite positions for pressing a pair of
built-in components respectively against parisons (two shells)
transferred onto the mold pieces and thereby securing the built-in
components respectively to the parisons. JP 2009-542480 also
describes a technique of coupling the opposed built-in components
when closing the mold pieces.
[0007] According to the technique of JP 2009-542480 of coupling the
built-in components when closing the mold pieces, however, in some
cases, it may be difficult to keep accurately the two built-in
components in the intended relative positions when coupling them
because those parions, immediately after transferred onto the mold
pieces, have a high fluidity due to a heat of the mold pieces. For
example, when the built-in components collide with each other
because of axial displacement of the built-in components when these
built-in components are coupled, irregularities may occur around
the areas of the parisons in which the built-in components are
embedded even if a collision force is small. As a result, the
built-in components may be inclined, and consequently, a layered
structure (in general, made of a plurality of materials and a
plurality of layers in the case of a fuel tank) of the parions may
be disturbed.
[0008] The present invention has been made to solve the above
drawback. It is an object of the present invention to provide a
method for coupling built-in components in a hollow container,
which can realize a reduction in irregularities around areas of a
wall of the container in which the built-in components are
embedded, and a reduction in inclination of the built-in
components.
SUMMARY OF THE INVENTION
[0009] In one aspect of the present invention, there is provided a
method for coupling built-in components in a hollow container,
comprising: a hollow container forming step of forming the hollow
container, the hollow container forming step including securing the
built-in components to parisons transferred onto mold pieces and
closing the mold pieces with the built-in components in a pre-in
the pre-coupled state state; and a built-in components coupling
step of coupling the built-in components, the built-in components
coupling step including pressing an outer surface of the hollow
container to displace the hollow container while cooling the hollow
container after removing the hollow container from the mold
pieces.
[0010] According to the method of the present invention, the
built-in components are secured in the pre-coupled state to the
parisons that have a relatively high fluidity due to the heat of
the mold pieces. Accordingly, irregularities of the parions and
inclination of the built-in components that are otherwise caused by
collision at the time of coupling of the built-in components do not
occur. The built-in components are coupled while the hollow
container is being cooled by the air or the like after being
removed from the mold pieces. Thus, even if the built-in components
collide with each other at the time of coupling thereof,
irregularities hardly occur to the wall of the hollow container
because of a reduced fluidity of the wall of the container and as a
result, the built-in components can be secured stably to the hollow
container.
[0011] The method according to the present invention may be
constituted in such a manner that in the built-in components
coupling step, a correction jig is prepared, the correction jig
including a lower jig and a upper jig, the lower jig being for
placing the hollow container thereon, the upper jig being movable
up and down and having a pressing portion for pressing the outer
surface of the hollow container,
[0012] the built-in components coupling step further including:
[0013] placing the hollow container on the lower jig with the
built-in components located at an upper surface part and a lower
surface part of the hollow container; and
[0014] then bringing the upper jig and the lower jig into proximity
with each other to cause the pressing portions to press only an
area of the upper surface part of the hollow container for
correcting the hollow container, the upper surface part area being
a bearing surface to which the built-in component is secured and a
surrounding area thereof.
[0015] The method of the present invention allows the correction
jig to have a simple structure. Accordingly, costs for correcting
the hollow container can be reduced. Further, for coupling the
built-in components, the pressing portion presses only the area of
the upper surface part of the hollow container that is a bearing
surface to which the built-in component is secured and a
surrounding area thereof. Thus, the hollow container only needs to
be corrected and deformed to a minimum degree. Further, since only
the limited area is corrected and deformed, it is easy to grasp the
variations in the amount of deformation due to correction. As a
result, it is easy to adjust the amount of deformation due to
correction.
[0016] Further, the method according to the present invention may
be constituted in such a manner that a pair of tubes are coupled
for communication with each other when the built-in components are
coupled during the built-in components coupling step.
[0017] According to the method of the present invention, the pair
of tubes can be coupled for communication with each other by
coupling the built-in components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1A-1G are schematic diagrams showing a hollow
container forming step, the hollow container shown from the
side.
[0019] FIGS. 2A-2C are schematic diagrams showing a built-in
components coupling step, the hollow container shown from the
side.
[0020] FIG. 3 is a side view of a part of the hollow container with
the built-in components in the coupled state according to a first
embodiment.
[0021] FIG. 4 is a perspective view of outer appearances of the
built-in components according to the first embodiment.
[0022] FIGS. 5A-5D are side views of the entirety of the hollow
container with the built-in components in the coupled state
according to a second embodiment to a fifth embodiment.
[0023] FIGS. 6A and 6B are side views of parts of the hollow
container with the built-in components, which are in the
pre-coupled state and in the coupled state, respectively, according
to the second embodiment.
[0024] FIGS. 7A and 7B are side views of parts of the hollow
container with the built-in components, which are in the
pre-coupled state and in the coupled state, respectively, according
to the third embodiment.
[0025] FIGS. 8A and 8B are side views of parts of the hollow
container with the built-in components, which are in the
pre-coupled state and in the coupled state, respectively, according
to the fifth embodiment.
[0026] FIGS. 9A and 9B are side views of parts of the hollow
container with the built-in components, which are in the
pre-coupled state and in the coupled state, respectively, according
to a sixth embodiment.
[0027] FIGS. 10A and 10B are side views of parts of the hollow
container with the built-in components, which are in the
pre-coupled state and in the coupled state, respectively, according
to a seventh embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] A method for coupling built-in components in a hollow
container according to the present invention comprises a hollow
container forming step of forming a hollow container shown in FIGS.
1A-1G and a built-in components coupling step of coupling the
built-in components shown in FIGS. 2A-2C. The hollow container
intended in the present invention is, for example, a blow molded
article such as a vehicle fuel tank or the like. The hollow
container forming step shown in FIGS. 1A-1G is a step of forming a
blow molded article.
<Hollow Container Forming Step>
[0029] The hollow container forming step shown in FIGS. 1A-1G
includes securing built-in components (in this case, first built-in
components 2 and second built-in components 3) to parisons P,P
transferred onto mold pieces 11,11; and closing the mold pieces
11,11 with each of the first built-in components 2 and a
corresponding one of the second built-in components 3 in the
pre-coupled state, thereby forming a hollow container 1.
[0030] In the case where the hollow container 1 is a vehicle fuel
tank, examples of materials of the first built-in components 2 and
the second built-in components 3 include, for example, POM
(polyacetal resin). The parisons P,P each have a sectional
multilayered structure in which a barrier layer made of a material
with a high impermeability to fuel is sandwiched between at least a
thermoplastic resin inner layer and a thermoplastic resin outer
layer. Herein, the thermoplastic resin inner layer constitutes an
inner surface of the tank and the thermoplastic resin outer layer
constitutes an outer surface thereof. The thermoplastic resin inner
layer and the thermoplastic resin outer layer are each made of, for
example, PE (high-density polyethylene) excellent in heat fusion
and molding properties.
[0031] FIG. 1A shows a state in which the blow mold pieces 11,11
are opened and a center frame 12 is positioned between the opened
mold pieces 11,11, with a pair of plate-like first and second
parisons P,P each hung between the respective mold pieces 11,11 and
the center frame 12. The center frame 12 is provided with two
cylinders 13 a and two cylinders 13b. The two cylinders 13a serve
as actuators for securing the two first built-in components 2 to
the first parison P. The two cylinders 13b serve as actuators for
securing the two second built-in components 3 to the second parison
P. The cylinders 13a and 13b have rods, respectively, that are
provided with releasable holding mechanisms 14 at top ends thereof,
respectively. The clamp mechanisms 14 of the cylinders 13a hold the
built-in components 2, whereas the clamp mechanisms 14 of the
cylinders 13b hold the built-in components 3. In FIG. 1A, the rods
of the cylinders 13a and 13b are in the retracted state. Detailed
description of the clamp mechanism 14 is omitted since it is
irrelevant to an understanding of the present invention.
[0032] FIG. 1B shows a state the mold pieces 11,11 are moved from
the state shown FIG. 1A to be closed with the center frame 12
sandwiched therebetween, and sealed spaces are formed between the
mold surfaces and the parisons P,P by sealingly attaching the mold
surfaces of the mold pieces 11,11 to the parisons P,P. By drawing a
vacuum in those spaces from the mold surface sides of the closed
mold 11, the parisons P,P are transferred onto the mold surfaces of
the mold pieces 11,11 as shown in FIG. 1C.
[0033] Next, as shown in FIG. 1D, the rods of the cylinders 13a and
13b are advanced horizontally by a predetermined length so that the
base ends of the first built-in components 2 and the second
built-in components 3 are pressed against the parisons P,P and
embedded therein to a predetermined depth. Then, the first built-in
components 2 and the second built-in components 3 are released by
the clamp mechanisms 14. After that, the rods of the cylinders 13a
and 13b are retracted as shown in FIG. 1E. Then, as shown in FIG.
1F, the mold pieces 11,11 are opened, and the center frame 12 is
withdrawn from between the mold pieces 11,11. Next, as shown in
FIG. 1G, the mold pieces 11,11 are closed again to define a cavity
inside them. Then, air is blown into the cavity to transform the
parisons P,P into a hollow container 1.
[0034] In the case where the hollow container 1 has a flat shape as
that of a vehicle fuel tank, the hollow container 1 is positioned
with flat planes thereof vertically extending when it is formed by
using the mold pieces 11,11. Thus, it is possible that the first
built-in components 2 are secured to one flat plane of the hollow
container 1 and the second built-in components 3 are secured to the
other flat plane thereof. As is clear from FIG. 1G, in contrast to
a predetermined coupled state thereof, the first built-in
components 2 and the second built-in components 3 are left in the
pre-coupled state with a gap L formed therebetween during the
hollow container forming step after closing the mold pieces 11,11.
This pre-coupled state of the first built-in components 2 and the
second built-in components 3 continues until the next step of
coupling the built-in components is finished after the mold pieces
11,11 are opened and the hollow container 1 is removed from between
the opened mold pieces 11,11.
<Built-in Components Coupling Step>
[0035] The built-in components coupling step shown in FIGS. 2A-2C
is a step of coupling, when the hollow container 1 removed from the
mold pieces 11,11 (FIGS. 1A-1G) is allowed to cool, each of the
first built-in components 2 and a corresponding one of the second
built-in components 3 by pressing the outer surface of the hollow
container 1 to deform hollow container 1. In FIGS. 2A-2C,
illustrations of pinch-off portions of the hollow container are
omitted.
[0036] The hollow container 1 removed from the mold pieces 11,11
shown in FIGS. 1A-1G is transferred into a correction jig 15 shown
in FIGS. 2A-2C. The hollow container 1 may be transferred from the
mold pieces 11,11 into the correction jig 15, either totally
automatically, for example, by means of a robot, a conveyor or the
like, or manually. The hollow container 1 soon after removed from
the mold pieces 11,11 and formed has a surface temperature ranging
from approximately 80.degree. C. to approximately 120.degree. C.
This means that in the case where the hollow container 1 is
transferred manually, an operator needs to wear work gloves in
handling the hollow container 1.
[0037] There is no particular limitation on the structure of the
correction jig 15 as long as it has a function of correcting the
hollow container 1 by pressing the outer surface of the hollow
container 1 and thereby coupling each of the first built-in
components 2 and a corresponding one of the second built-in
components 3. The correction jig 15 shown in FIGS. 2A-2C is
constituted of a movable upper jig 16 that can move up and down and
a fixed lower jig 17. The lower jig 17 includes a fixed base 18 and
a mount 19 provided thereon. The mount 19 is for placing the hollow
container 1 thereon. In the case where the hollow container 1 has a
flat shape as that of a vehicle fuel tank, the hollow container 1
is placed on the mount 19 with the flat planes thereof extending
horizontally. FIGS. 2A-2C shows an embodiment in which the hollow
container 1 is placed on the mount 19 in such a manner that one
flat plane of the hollow container 1 with the first built-in
components 2 serves as a lower surface part and abuts on the mount
19 whereas the other flat plane thereof with the second built-in
components 3 serves as an upper surface part. The mount 19 is
properly provided with a pair of upstanding guide walls 20 opposed
to the inner side walls of the hollow container 1. The pair of
upstanding guide walls 20 are for positioning the hollow container
1. Further, the fixed base 18 is provided with stoppers 21 for
determining the lowest position to which the upper jig 16 is
allowed to move down.
[0038] On the other hand, the upper jig 16 includes a movable base
22 and pressing portions 23. The movable base 22 is moved up and
down by an actuator such as a cylinder, not shown. The pressing
portions 23 are provided at a lower surface of the movable base 22.
The pressing portions 23 press the upper surface part of the hollow
container 1 toward the lower surface part thereof when the movable
base 22 is moved down for coupling each of the second built-in
components 3 to a corresponding one of the first built-in
components 2. The pressing portions 23 each are formed with a
horizontal pressing surface 23a. The pressing surfaces 23a press
only local areas of the upper surface part of the hollow container
1, more specifically, only areas that are bearing surfaces to which
the second built-in components 3 are secured and surrounding areas
thereof. FIGS. 2A-2C shows an embodiment in which a horizontally
extending support plate 24 is attached to the lower surface of the
movable base 22 and the pressing portions 23 are attached to the
lower surface of the support plate 24. Each of the pressing
portions 23 includes a vertically extending pressing pillar 25 and
a horizontally extending pressing plate 26. The pillars 25 are
attached to the lower surface of the support plate 24. The pressing
plates 26 are attached to the lower ends of the pressing pillars
25, respectively. The lower surface of the pressing plate 26
constitutes the pressing surface 23a. An adjustment shim plate (not
shown) is interposed, for example, between the support plate 24 and
the pressing pillars 25. The adjustment shim plate is for adjusting
the pressure to be applied by the pressing surface 23a to the upper
surface part of the hollow container 1. Further, the movable base
22 is provided with stoppers 27 that abut on the stoppers 21.
[0039] There will be described one example of the built-in
components coupling step that uses the correction jig 15. The
hollow container 1 such as a fuel tank, removed from the mold
pieces 11,11 (FIGS. 1A-1G) and having a surface temperature ranging
from approximately 80.degree. C. to approximately 120.degree. C.,
is placed on the mount 19 of the lower jig 17, with the upper jig
16 lifted up, as shown in FIG. 2A. In this state, each of the first
built-in components 2 and a corresponding one of the second
built-in components 3 are in the pre-coupled state, with the gap L
formed therebetween. Then, as shown in FIG. 2B, the upper jig 16 is
moved down until the stoppers 21 and the stoppers 27 abut on each
other. The pressing plates 26 press only the local areas of the
upper surface part of the hollow container 1, more specifically,
only the areas that are the bearing surfaces to which the second
built-in components 3 are secured and surrounding areas thereof.
Those pressed areas that are the bearing surfaces and the
surrounding areas thereof are corrected and deformed to be
displaced downward by a pressing force from the pressing plates 26.
The downward displacement reduces the gap L to approximately zero,
and thus, the first built-in components 2 and the second built-in
components 3 are brought into the predetermined coupled state.
[0040] In the present embodiment, the cooling in the built-in
components coupling step is, for example, natural cooling in an
ambient air. Here, the hollow container 1 being corrected by the
pressing portions 23 has still a surface temperature ranging from
approximately 80.degree. C. to approximately 120.degree. C. This
allows the outer shape of the hollow container 1 of a thermoplastic
resin material to be sufficiently corrected and deformed. The
duration for the upper jig 16 to stay at the lowest position, that
is, the duration for the pressing plates 26 at the lowest position
to keep pressing the upper surface part of the hollow container 1,
is set properly for ensuring completion of the deformation due to
correction of the outer shape of the hollow container 1 made of a
thermoplastic resin material. In other words, the pressing plates
26 keep pressing until the deformation due to correction is
finished to such a degree that there is no spring back occurring at
those pressed areas that are the bearing surfaces and the
surrounding areas thereof, and to such a degree that the firmly
coupled state of the first built-in components 2 and the second
built-in components 3 is ensured.
[0041] In some cases, by carrying out a treatment such as blowing a
cooling air to the hollow container 1 when the pressing plates 26
at the lowest position is pressing the upper surface part of the
hollow container 1, the cooling of the hollow container is
accelerated to shorten the time required for completing the
deformation of the areas to be corrected. As a result, the duration
for the upper jig 16 to stay at the lowest position is shortened.
Consequently, the time required for the built-in components
coupling step is reduced. The blowing of a cooling air to the
hollow container 1 may be started before the correction of the
hollow container 1 shown in FIG. 2A.
[0042] Then, after the lapse of the duration for the upper jig 16
to stay at the lowest position, the upper jig 16 is lifted up as
shown in FIG. 2C and the hollow container 1 is removed from the
mount 19 and transferred for the next step. In the corrected hollow
container 1, those pressed areas that are the bearing surfaces to
which the second built-in components 3 are secured and the
surrounding areas thereof are displaced inwardly of the hollow
container 1 relative to their initial state by the length
approximately equal to the gap L.
[0043] As has been described above, in the present invention,
first, during the hollow container forming step of forming the
hollow container, the hollow container 1 is formed by using the
mold pieces 11,11, with the first built-in components 2 and the
second built-in components 3 in the pre-coupled state. The parisons
P,P transferred onto the mold pieces 11,11 have a relatively high
fluidity due to the heat from the mold pieces 11,11. If the first
built-in components 2 and the second built-in components 3 are to
be coupled in this state as with the conventional technique, when
the first built-in components 2 and the second built-in components
3 collide with each other, there is a risk that irregularities may
occur around the areas of the parisons P,P in which the first
built-in components 2 and the second built-in components 3 are
embedded. As a result, the first built-in components 2 and the
second built-in components 3 may be inclined, even if the collision
force is small. In contrast, in the present invention, during the
hollow container forming step of forming the hollow container 1 by
using the mold pieces 11,11, the first built-in components 2 and
the second built-in components 3 are in the pre-coupled state.
Consequently, there are less possibilities to cause problems of
irregularities in the parions P,P and inclination of the first
built-in components 2 and the second built-in components 3.
[0044] In the hollow container 1 removed from the mold pieces
11,11, the fluidity of the wall is reduced when the hollow
container 1 is exposed to the air and allowed to cool. According to
the present invention, the first built-in components 2 and the
second built-in components 3 are coupled when the hollow container
is being allowed to cool. Thus, even if the first built-in
components 2 and the second built-in components 3 collide at the
time of coupling thereof, irregularities hardly occur to the wall
of the hollow container 1 because the wall of the hollow container
1 has a reduced fluidity. As a result, the first built-in
components 2 and the second built-in components 3 are coupled
stably.
[0045] In the present embodiment, the built-in components coupling
step, by using the correction jig 15 having the upper jig 16 and
the lower jig 17 is as follows. First, the hollow container 1 is
placed on the lower jig 17 (the mount 19) with the second built-in
components 3 located at the upper surface part of the hollow
container 1 and with the first built-in components 2 located at the
lower surface part thereof. Then, the upper jig 16 and the lower
jig 17 are brought into proximity with each other. More
specifically, the upper jig 16 is moved down to cause the pressing
portions 23 to press only the local areas of the upper surface part
of the hollow container 1, more specifically, only the areas that
are the bearing surfaces to which the second built-in components 3
are secured and the surrounding areas thereof. By the pressing
portions 23 pressing those areas, the hollow container 1 is
corrected to couple the first built-in components 2 and the second
built-in components 3. According to the present embodiment, the
correction jig 15 has a simple structure, and thus, costs for
correcting the hollow container 1 can be reduced. Further, for
coupling the first built-in components 2 and the second built-in
components 3, the pressing portions 23 press only the local areas
of the upper surface part of the hollow container 1, more
specifically, only the areas that are the bearing surfaces to which
the second built-in components 3 are secured and the surrounding
areas thereof. Thus, the hollow container 1 only needs to be
corrected and deformed to a minimum degree. Since only the limited
areas are corrected and deformed, it is easy to grasp the
variations in the amount of deformation due to correction. This
also facilitates adjustment of the amount of deformation due to
correction by the adjustment shim plate or the like.
<Embodiments of First Built-in Component 2 and Second Built-in
Component 3>
[0046] Next, description will be made of a plurality of embodiments
of the first built-in component 2 and the second built-in component
3 when the hollow container 1 is a vehicle fuel tank T.
First Embodiment
[0047] The first built-in component 2 and the second built-in
component 3 shown in FIGS. 3 and 4 are constituted of a first
support 4 and a second support 5, respectively. The first support 4
and the second support 5 are coupled to erect vertically across the
distance between a lower surface part Ta and an upper surface part
Tb of the fuel tank T. The first support 4 and the second support 5
function to prevent shrink deformation of the fuel tank T. The
first support 4 and the second support 5 each may have, for
example, a cylindrical shape, and may be a hollow member or a solid
member.
[0048] The first support 4 and the second support 5 have base end
surfaces to be embedded in the lower surface part Ta and the upper
surface part Tb of the fuel tank T. The base end surface of each of
the first support 4 and the second support 5 is formed with a pair
of hook portions 7. The hook portions 7 have hook tips opposed to
each other to form a resin inflow groove 6 with a narrow entrance.
Shown in FIGS. 3 and 4 is an embodiment in which the pair of hook
portions 7 comprises four pairs of hook portions 7 arranged in
parallel to each other to form four resin inflow grooves 6. Each
hook portion 7 has a linear cross section. In the hollow container
forming step of forming the hollow container 1 shown in FIGS.
1A-1G, when the rods of the cylinders 13a and 13b move forward to
press the base ends of the first support 4 and the second support 5
against the parisons P,P, part of the parisons P,P flows into the
resin inflow grooves 6. As a result, the first support 4 and the
second support 5 are firmly fixed to the parisons P,P (that is, the
lower surface part Ta and the upper surface part Tb) because of a
mechanical coupling force applied by the pair of hook portions
7.
[0049] On the other hand, the top ends of the first support 4 and
the second support 5 are provided with a coupling means. The
coupling means is constituted of, for example, a projection and a
recess. The projection is formed on either one of the first support
4 and the second support 5 and the recess is formed in the other of
the first support 4 and the second support 5. The projection fits
in the recess. FIGS. 3 and 4 show an embodiment in which a circular
coupling hole 8 serving as the recess and a columnar coupling
protrusion 9 are formed. The circular coupling hole 8 is formed in
the center of the top end surface of the second support 5. The
columnar coupling protrusion 9 is formed in the center of the top
end surface of the first support 4. The columnar coupling
protrusion 9 fits in the coupling hole 8. When the hollow container
forming step of forming the hollow container is finished, part of
the top end of the coupling protrusion 9 is inside the coupling
hole 8, although the top end surfaces of the first support 4 and
the second support 5 are spaced apart from each other by the gap L
shown in FIGS. 1A-1G and thus are in the pre-coupled state. By
correcting the fuel tank T in the built-in components coupling
step, the top end surfaces of the first support 4 and the second
support 5 make an approximately face-to-face contact with each
other to reduce the gap L to approximately zero. Thus, the coupling
protrusion 9 completely fits in the coupling hole 8, so that the
first support 4 and the second support 5 are coupled. As a result,
the first support 4 and the second support 5 serve as one firm
support to support the lower surface part Ta and the upper surface
part Tb of the fuel tank T. The value of the gap L is properly
set.
[0050] In the present invention, the "coupled state" of the first
built-in components 2 and the second built-in components 3 refers
to a state that allows the function the first built-in components 2
and the second built-in components 3 to be performed only after the
first built-in components 2 and the second built-in components 3
are coupled to serve as an integral unit. For example, in the first
embodiment, the first support 4 and the second support 5 perform a
function as one firm support only after the top end surfaces of the
first support 4 and the second support 5 make an approximately
face-to-face contact with each other. Accordingly, even if part of
the top end of the coupling protrusion 9 is inside the coupling
hole 8 before the fuel tank T is corrected, when the top end
surfaces of the first support 4 and the second support 5 are spaced
apart from each other by the gap L, the first support 4 and the
second support 5 do not function as one support with a given
rigidity and thus regarded as being in the "pre-coupled" state.
Second Embodiment
[0051] FIGS. 5A, 6A and 6B are schematic diagrams showing the
second embodiment. FIG. 5A is a side view of the entirety of the
hollow container with the built-in components in the coupled state.
FIGS. 6A and 6B are side views of parts of the hollow container
with the built-in components, which are in the pre-coupled state
and in the coupled state, respectively, according to the second
embodiment. In FIGS. 5A, 6A and 6B, the same components as those in
the first embodiment are signified by the same References, and
descriptions thereof are omitted. The second embodiment is the same
as the first embodiment in that the first built-in component 2 and
the second built-in component 3 are constituted of the first
support 4 and the second support 5, respectively, and that the
first support 4 and the second support 5 are coupled to erect
vertically across the distance between the lower surface part Ta
and the upper surface part Tb of the fuel tank T.
[0052] In the second embodiment, when the first support 4 and the
second support 5 are coupled, a pair of tubes are coupled for
communication with each other. The first support 4 and the second
support 5 each have a side surface with a tube holding stay 31
fixed thereto. The tube holding stay 31 of the first support 4
holds a portion of a first tube 32 that is near an upwardly open
end thereof. The tube holding stay 31 of the second support 5 holds
a portion of a second tube 33 that is near a downwardly open end
thereof. The open end of the first tube 32 is formed as a male
mouthpiece 32a and the open end of the second tube 33 is formed as
a female mouthpiece 33a.
[0053] Before the fuel tank T is corrected, as shown in FIG. 6A,
the first support 4 and the second support 5 are in the pre-coupled
state, and the first tube 32 and the second tube 33 are not
communicated. When the first support 4 and the second support 5 are
coupled by the correction of the fuel tank T, as shown in FIG. 6B,
the male mouthpiece 32a fits in the female mouthpiece 33a, so that
the first tube 32 and the second tube 33 are communicated with each
other. There is no particular limitation on the connection
structures of other ends of the first tube 32 and the second tube
33. For example, after the built-in components coupling step, as
shown in FIG. 5A, the other end of the first tube 32 is manually
connected to a valve V, whereas the other end of the second tube 33
is manually connected to an apparatus or piping, not shown, around
a predetermined opening 34 of the fuel tank T. Examples of the
valve V include a cut valve and the like.
[0054] According to the second embodiment, various tubes laid
inside the fuel tank T can be supportedly fixed to the first
support 4 and the second support 5.
Third Embodiment
[0055] FIGS. 5B, 7A and 7B are schematic diagrams showing the third
embodiment. FIG. 5B is a side view of the entirety of the hollow
container with the built-in components in the coupled state. FIGS.
7A and 7B are side views of parts of the hollow container with the
built-in components, which are in the pre-coupled state and in the
coupled state, respectively, according to the third embodiment. In
FIGS. 5B, 7A and 7B, the same components as those in the second
embodiment are signified by the same References, and descriptions
thereof are omitted. The third embodiment is the same as the second
embodiment in that the first built-in component 2 and the second
built-in component 3 are constituted of the first support 4 and the
second support 5, respectively; and that the first support 4 and
the second support 5 are coupled to erect vertically across the
distance between the lower surface part Ta and the upper surface
part Tb of the fuel tank T; and that when the first support 4 and
the second support 5 are coupled, the pair of tubes are coupled for
communication with each other.
[0056] In the second embodiment, each of the tube holding stays 31
holds the portion of the first tube 32 that is near the upwardly
open end thereof and the portion of the second tube 33 that is near
the downwardly open end thereof that are located outside the first
support 4 and the second support 5. In the third embodiment, the
portion of the first tube 32 that is near the upwardly open end
thereof and the portion of the second tube 33 that is near the
downwardly open end thereof are located inside the first support 4
and the second support 5. More specifically, the first tube 32
extends through the side wall of the first support 4 to the end
provided inside the coupling protrusion 9. The coupling protrusion
9 is upwardly opened. On the other hand, the second tube 33 extends
through the side wall of the second support 5 to the end inside the
coupling hole 8.
[0057] Before the fuel tank T is corrected, as shown in FIG. 7A,
the first support 4 and the second support 5 are in the pre-coupled
state, and the first tube 32 and the second tube 33 are not
communicated. When the first support 4 and the second support 5 are
coupled by the correction of the fuel tank T, as shown in FIG. 7B,
the male mouthpiece 32a fits in the female mouthpiece 33a, so that
the first tube 32 and the second tube 33 are communicated with each
other. There is no particular limitation on the connection
structures of other ends of the first tube 32 and the second tube
33. For example, after the built-in components coupling step, as
shown in FIG. 5B, the other end of the first tube 32 is manually
connected to a predetermined opening 35 of the fuel tank T while
the other end of the second tube 33 is manually connected to the
valve V.
Fourth Embodiment
[0058] FIG. 5C is a side view of the entirety of the hollow
container with the built-in components in the coupled state in the
fourth embodiment. In the fourth embodiment, the second built-in
component 3 is provided with the valve V. A first support 36
constitutes the first built-in component 2. A second support 37
constitutes the second built-in component 3. The first support 36
and the second support 37 are coupled to erect vertically across
the distance between a lower surface part Ta and an upper surface
part Tb of the fuel tank T. The second support 37 has the valve V.
The valve V may be provided directly inside the second support 37
or inside a casing for the valve V. If the valve V is provided
inside the casing, the casing may be incorporated into the second
support 37 that constitutes the second built-in component 3.
[0059] According to the fourth embodiment, the first support 36 and
the second support 37 serve to prevent shrink deformation of the
fuel tank T and also to reduce inclination of the valve V relative
to the wall of the fuel tank T. As a result, the valve V stably
opens and closes.
[0060] It is possible to incorporate, as well as the valve V, a
fuel pump, a canister and the like into either one or each of the
first support 36 and the second support 37. Further, one support
may be directly connected to the valve V, the fuel pump, the
canister or the like. In such a case, the valve, the fuel pump, the
canister or the like serves as one of the built-in components,
while the support serves as the other built-in component.
Fifth Embodiment
[0061] FIGS. 5D, 8A and 8B are schematic diagrams showing the fifth
embodiment. FIG. 5D is a side view of the entirety of the hollow
container with the built-in components in the coupled state. FIGS.
8A and 8B are side views of parts of the hollow container with the
built-in components, which are in the pre-coupled state and in the
coupled state, respectively, according to the fifth embodiment. In
the fifth embodiment, by coupling the first built-in components 2
and the second built-in components 3, a support with a damper
function is formed across the distance between the lower surface
part Ta and the upper surface part Tb of the fuel tank T.
[0062] The first built-in component 2 is constituted of a first
support 38. The first support 38 has a pair of damper arms 41 at a
top end thereof. The pair of damper arms 41 extend in diagonally
upward directions. The second built-in component 3 is constituted
of a second support 39. The second support 39 has a pair of damper
arms 41 at a bottom end thereof. The pair of damper arms 41 extend
in diagonally downward directions. The damper arms 41 in opposite
positions have top end surfaces with a coupling means. The coupling
means is constituted of, for example, a projection and a recess. In
FIGS. 8A and 8B, coupling holes 43 are formed in the top end
surfaces of the damper arms 41 of the second support 39, and the
coupling protrusions 42 are formed on the top end surfaces of the
damper arms 41 of the first support 38. The coupling protrusions 42
fit in the coupling holes 43.
[0063] Before the fuel tank T is corrected, as shown in FIG. 8A,
the top end surfaces of the damper arms 41 in opposite positions
are spaced apart from each other by the gap L, and the first
support 38 and the second support 39 are in the pre-coupled state.
Due to the correction of the fuel tank T, as shown in FIG. 8B, the
coupling protrusions 42 fit in the coupling holes 43 to cause the
top end surfaces of the damper arms 41 to make an approximately
face-to-face contact with each other and thereby reduce the gap L
to approximately zero. Thus, the first support 38 and the second
support 39 are coupled. As a result, the support with a damper 40
is formed across the distance between the lower surface part Ta and
the upper surface part Tb of the fuel tank T. The damper 40 has an
approximately rhombus frame-like shape. Because the support has the
damper 40, in the event that an external force is suddenly applied
to the fuel tank T, the external force is buffered to prevent
sudden shrink deformation of the fuel tank T.
Sixth Embodiment
[0064] FIGS. 9A and 9B are schematic diagrams showing the sixth
embodiment. FIGS. 9A and 9B are side views of parts of the hollow
container with the built-in components, which are in the
pre-coupled state and in the coupled state, respectively, according
to a sixth embodiment. In the sixth embodiment, an engagement means
53 is provided. The engagement means 53 is for positioning the
first built-in component 2 and the second built-in component 3
relative to each other and engaging the first built-in component 2
and the second built-in component 3 with each other, with elastic
deformation of at least one of the first built-in component 2 and
the second built-in component 3, and preventing the first built-in
component 2 and the second built-in component 3 from moving closer
to each other and moving more apart from each other. A second
support 52 serves as the second built-in component 3. The first
support 51 has a top end formed with a spherical engagement
projection 54. The second support 52 has a top end formed with an
engagement recess 55. The engagement recess 55 has a spherical
space with a narrow entrance. The engagement means 53 is
constituted of the engagement projection 54 and the engagement
recess 55.
[0065] Before the fuel tank T is corrected, as shown in FIG. 9A,
the engagement projection 54 and the engagement recess 55 are not
engaged, and the first support 51 and the second support 52 are in
the pre-coupled state. In the correction of the fuel tank T, the
engagement projection 54 presses the peripheral area of the
entrance of the engagement recess 55 to enlarge the diameter of the
entrance of the engagement recess 55 with elastic deformation. As a
result, as shown in FIG. 9B, the engagement projection 54 is
engaged with the engagement recess 55, so that the first support 51
and the second support 52 are coupled. Consequently, the first
support 51 and the second support 52 are positioned and engaged and
prevented from moving closer to each other and moving more apart
from each other. This prevents shrink deformation of the fuel tank
T (deformation defined as a decrease in the distance between the
lower surface part Ta and the upper surface part Tb) and also
expansion deformation of the fuel tank T (deformation defined as an
increase in the distance between the lower surface part Ta and the
upper surface part Tb).
[0066] In addition, the engagement recess 55 may be formed in the
first support 51 and the engagement projection 54 may be formed on
the second support 52.
Seventh Embodiment
[0067] FIGS. 10A and 10B are schematic diagrams showing the seventh
embodiment. FIGS. 10A and 10B side views of parts of the hollow
container with the built-in components, which are in the
pre-coupled state and in the coupled state, respectively, according
to a seventh embodiment. In the seventh embodiment as well, the
engagement means 53 is provided for positioning and engaging the
first built-in component 2 and the second built-in component 3 with
elastic deformation of at least one of the first built-in component
2 and the second built-in component 3 and preventing the first
built-in component 2 and the second built-in component 3 from
moving closer to each other and moving more apart from each other.
In the sixth embodiment, the engagement means 53 is constituted of
the spherical engagement projection 54 and the engagement recess 55
that has a spherical space. In the seventh embodiment, the
engagement means 53 is constituted of engagement hooks 64 and
engagement holes 65. A first support 61 serves as the first
built-in component 2. A second support 62 serves as the second
built-in component 3. The first support 61 has a top end portion
with engagement hooks 64 projecting around the side surface
thereof. The second support 62 has a top end portion with
engagement holes 65 formed through the side surface thereof.
[0068] Before the fuel tank T is corrected, as shown in FIG. 10A,
the engagement hooks 64 and the engagement holes 65 are not engaged
with each other, and the first support 61 and the second support 62
are in the pre-coupled state. In the correction of the fuel tank T,
the diameter of the top end portion of the first support 61 is
shrunk with elastic deformation and that of the top end portion of
the second support 62 is enlarged with elastic deformation. As a
result, as shown in FIG. 10B, the engagement hooks 64 are engaged
with the engagement holes 65, so that the first support 61 and the
second support 62 are coupled. Consequently, the first support 61
and the second support 62 are positioned and engaged and prevented
from moving closer to each other and moving more apart from each
other. This prevents shrink deformation of the fuel tank T
(deformation defined as a decrease in the distance between the
lower surface part Ta and the upper surface part Tb) and also
expansion deformation of the fuel tank T (deformation defined as an
increase in the distance between the lower surface part Ta and the
upper surface part Tb).
[0069] The engagement holes 65 may be formed through the first
support 61 and the engagement hooks 64 may be formed on the second
support 62.
[0070] The engagement means 53 is for positioning and engaging the
first built-in component 2 and the second built-in component 3 with
elastic deformation of at least one of the first built-in component
2 and the second built-in component 3 and preventing the first
built-in component 2 and the second built-in component 3 from
moving closer to each other and moving more apart from each other.
The engagement means 53 is also applicable not only to a mode in
which the tubes are communicated with each other as in the second
embodiment and the third embodiment but also to a mode in which the
valve V or the like is incorporated in the first built-in component
2 or the second built-in component 3 as in the fourth embodiment
and to a mode in which the support with the damper function is
formed as in the fifth embodiment.
[0071] In the above, the preferred embodiments of the present
invention have been described. The first built-in component 2 and
the second built-in component 3 serving as the built-in components
are not limited to those described in the first embodiment to
seventh embodiment but may be any that is built in the hollow
container 1.
[0072] The method of the present invention can realize a reduction
in irregularities at the wall of the container and inclination of
the built-in components that occur during the coupling of the
built-in components.
[0073] The embodiments of the present invention have been explained
as aforementioned. However, the embodiment of the present invention
is not limited to those explanations, and those skilled in the art
ascertain the essential characteristics of the present invention
and can make the various modifications and variations to the
present invention to adapt it to various usages and conditions
without departing from the spirit and scope of the invention.
* * * * *